Dual Purpose Pie Carton

ABSTRACT

A carton suitable for both shipping and displaying an item, particularly a bake good, such as a pie, is disclosed. The carton includes a top panel a bottom panel, first and second side panels and first and second end panels. According to an embodiment, a detachable panel section is provided in the top panel and the first side panel, and a substantially transparent film is attached to an underside of the top panel and the first side panel behind the detachable panel section. The carton may be opened to remove the item contained therein for cooking or preparation. The carton can be converted to a display configuration by completely detaching the detachable panel section from a remainder of the carton such that the transparent film forms a display window. When the carton is in its display configuration, the item may be placed in the carton such that the item is visible through the display window.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/095,140, filed on Sep. 8, 2008, the entire disclosure of which isincorporated herein by reference.

BACKGROUND

The disclosure relates to a carton for shipping and displaying a fooditem.

Baked goods, such as frozen or refrigerated pies are often shipped to astore or restaurant in shipping cartons, and then removed from thecartons for baking in the store or restaurant. After being baked, thebaked goods are placed in display cartons for display and sale in thestore or restaurant. The use of separate boxes for shipping and displayresults in increased cost and waste.

It is therefore desirable to provide a carton that is suitable for bothshipping and display of a baked good.

SUMMARY

A carton for shipping and displaying a food item, such as a baked good,is disclosed. More specifically, the carton can be suitable for shippingand displaying a pie. The carton can be converted from a firstconfiguration for storing and/or shipping a food item to a secondconfiguration for displaying the food item. A blank assembly for formingthe carton, a method of for forming the carton from the blank assembly,and a method of preparing a food item for sale using the carton are alsodisclosed.

According to an embodiment, a carton can comprise a bottom panel, a toppanel, a first side panel, a second side panel, a first end panel formedby a first top end flap and a first bottom end flap, the first top endflap and the first bottom end flap being folded in overlappingrelationship, and a second end panel. The first top end flap cancomprise at least one tab and the first bottom end flap can comprise atleast one cutout. The carton can be converted from a first configurationin which the first top end flap and the first bottom end flap areadhesively secured together such that the first end panel is closed, toa second configuration in which the first top end flap and the firstbottom end flap are not adhesively secured together and the at least onetab is inserted in the at least one cutout such that the first end panelis closed.

According to an embodiment a carton can comprise a bottom panel, a toppanel, a first side panel, a second side panel, a first end panel, asecond end panel; and a detachable panel section in at least one of thetop panel, the first side panel, the second side panel, the first endpanel and the second end panel. The detachable panel section can bedefined by a tear pattern. A substantially transparent film can bepositioned behind the detachable panel section.

According to an embodiment, a carton blank assembly can include a blankcomprising a bottom panel, a first side panel foldably connected to thebottom panel, a top panel foldably connected to the first side panel,and a second side panel foldably connected to the top panel. The blankcan further comprise a first bottom end flap foldably connected to thebottom panel, a first top end flap foldably connected to the top panel,a second bottom end flap foldably connected to the bottom panel andcomprising at least one cutout, and a second top end flap foldablyconnected to the top panel and comprising at least one tab. Adhesive canbe disposed on either the first bottom end flap or the first top endflap.

The first top end flap and the first bottom end flap can be folded inoverlapping relationship and releasably, adhesively secured togetherwith the adhesive. The at least one tab can be inserted in the at leastone cutout to secure the first top end flap and the first bottom endflap together when the first top end flap and the first bottom end flapare not adhesively secured together.

According to an embodiment, a carton blank assembly can include a cartonblank comprising a bottom panel, a first side panel foldably connectedto the bottom panel, a top panel foldably connected to the first sidepanel, a second side panel foldably connected to the top panel, aplurality of end flaps, and a detachable panel section defined by a tearpattern in the blank. The assembly can include a substantiallytransparent film attached to an underside of the blank and disposedbehind the detachable top panel section.

According to an embodiment, a method of preparing a food item for salecan comprise transporting the food item to a location in a cartoncomprising a bottom panel, a top panel, a first side panel, a secondside panel, a first end panel, and a second end panel. The first endpanel can be formed by a top end flap and a bottom end flap, wherein thetop end flap and the bottom end flap are folded in overlappingrelationship and secured together by an adhesive bond. The method cancomprise breaking the adhesive bond and opening the first end panelafter transporting the carton to the location, removing the food itemfrom the carton after opening the first end panel, cooking the food itemafter removing the food item from the carton, placing the food iteminside the carton after cooking the food item, and, after placing thefood item inside the carton, reclosing the first end panel by insertingat least one tab of the top end flap in a corresponding cutout in thebottom end flap.

According to an embodiment, a method of preparing a food item for salecan comprise transporting the food item to a sale location in a cartoncomprising a bottom panel, a top panel, a first side panel, a secondside panel, a first end panel, a second end panel, a detachable panelsection, and a substantially transparent film positioned behind thedetachable panel section. The detachable panel section can be defined bya tear pattern and can be located in at least one of the top panel, thefirst side panel, the second side panel, the first end panel and thesecond end panel. The method can further comprise detaching thedetachable panel section after transporting the food item to the salelocation such that the food item can be viewed through the substantiallytransparent film.

Those skilled in the art will appreciate the above features andadvantages, as well as additional features and advantages upon readingthe following detailed description with reference to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a blank for forming a carton according to anembodiment.

FIG. 2 is a perspective view of a partially erected structure formedfrom the blank of FIG. 1.

FIG. 3 is a perspective view of a fully erected carton formed from theblank of FIG. 1, wherein the carton is in a shipping or storageconfiguration.

FIGS. 4-6 illustrate a process of opening the carton of FIG. 3 forremoving one or more items from the carton.

FIG. 7 shows the carton in a reclosed configuration for containing oneor more items that have been placed in the carton.

FIG. 8 illustrates the detachment of a detachable portion of a top panelof the carton.

FIG. 9 shows the carton in a display configuration, upon detachment ofthe detachable portion from the carton.

DETAILED DESCRIPTION

FIG. 1 shows an outer face of a blank 1 for forming a carton 200 (FIGS.2-8), according to an embodiment of the invention. The blank 1 includesa bottom panel 10, a first side panel 20 foldably connected to thebottom panel 10 by a fold line 14, a top panel 30 foldably connected tothe first side panel 20 by a fold line 22, and a second side panel 40foldably connected to the top panel 30 by a fold line 34. The blank 1further includes a first bottom end flap 50 and a second bottom end flap70 foldably connected to opposite ends of the bottom panel 30 byrespective fold lines 16, 18, and a first top end flap 60 and a secondtop end flap 80 foldably connected to opposite ends of the top panel 30by respective fold lines 36, 38. Fastening tabs 64 are foldablyconnected to a free end of the first top end flap 60 by a fold lines 62.First and second side end flaps 100, 110 are foldably connected to firstends of the first and second side panels 20, 40, respectively byrespective fold lines 26, 46. Third and fourth side end flaps 120, 130are foldably connected to second ends of the first and second sidepanels 20, 40, respectively, along fold lines 28, 48. A side flap 140 isfoldably connected to an outer edge of the bottom panel 10 by a foldline 12.

The fold lines 12, 14, 16, 18, 22, 26, 28, 34, 36, 38, 46, 48, 62 may becrease lines, perforated crease lines, perforated lines, crease-cutlines or score lines, for example. Fold lines 36, 38 may includerespective arc-shaped cut line segments 36 a, 38 a, which form vents inthe carton 200 for venting steam from the carton 200 when a warm bakedgood is placed in the carton 200.

The first and second top end flaps 60, 80 are configured for attachmentto the first and second bottom end flaps 50, 70, respectively, in afully erected carton 200 (FIGS. 3-9). The first bottom end flap 50includes adhesive regions 52 for adhesive attachment of the first topend flap 60 to the first bottom end flap 50. The adhesive regions 52each include a perimeter cut pattern 54 and a pattern of perforatedlines 56 within the cut pattern 54. The cut pattern 54 may extendpartially, for example about 50%, through the thickness of the blank 1.The pattern of perforated lines 56 may also extend partially, such asabout 30%, through the thickness of the blank. Adhesive may be applieddirectly on the adhesive regions 52, or on the inner side of the firsttop end flap 60. The cut patterns 54 and patterns of perforated lines 56promote stronger attachment of the first top end panel 60 to the firstbottom end panel 50. According to another embodiment (not shown), theadhesive regions 52 may be formed on the first top end flap 60 insteadof the first bottom end flap 50.

The first bottom end panel 50 also includes cutouts 58 configured toreceive the fastening tabs 64 when the adhesive bond between flaps 50,60 is broken in the erected carton 200, as will be described later.

The second bottom end flap 70 includes an adhesive region 72 foradhesive attachment of the second top end flap 80 to the second bottomend flap 70. The adhesive region 72 includes a pattern of perforatedlines 74. The pattern of perforated lines 74 may extend partially, forexample about 30%, through the thickness of the blank 1. Adhesive may beapplied directly on the adhesive regions 72, or on the inner side of thesecond top end flap 80.

The first and second side end flaps 100, 110 may include respectivenotches or cut-outs 102, 112, which effectively remove a part of theflaps 100, 110 so that the flaps 100, 110 do not cover or interfere withthe slots 58 in flap 50 when the flaps 100, 110 are folded in theerected carton 200.

The side flap 140 is configured for attachment to the second side panel40. An adhesive region 142 may be provided in the side flap 140 tosecure the side flap 140 to the second side panel 40.

The panels 10, 20, 30, 40 and flaps 50, 60, 70, 80, 100, 110, 120, 130,140 may be constructed of a paperboard or cardboard material, forexample. However, other suitably rigid, durable and foldable materialsmay be employed.

The blank 1 includes a detachable panel section 150. The detachablepanel section 150 includes a detachable top panel portion 30 a in thetop panel 30 and a detachable side panel portion 20 a in the first sidepanel 20 foldably connected to the section 30 a along the fold line 22.The detachable panel section 150 is defined by a tear pattern 152extending within the top panel 30 and the first side panel 20. In theexemplary embodiment of FIG. 1, the tear pattern 152 is substantiallyrectangular, which results in the panel section 150 having asubstantially rectangular shape. However other configurations and shapesare envisioned for the tear pattern 152 and the detachable panel section150. For example, it is possible for the panel section 150 to extendinto the first top end panel 60, the second top end panel 80 or thesecond side panel 40, or any one or combination of the panels 20, 30,40, 60, 80.

As will be described later in more detail, the panel section 150 isconfigured to be removed from the carton 200 (FIG. 8) to place thecarton 200 in a display configuration (FIG. 9), such that the detachabletop panel portion 30 a and the detachable side panel portion 20 b areseparated from the top panel 30 and side panel 20, respectively, leavinga non-detachable top panel portion 30 b and a non-detachable side panelportion 20 b with the carton 200. A cut-away corner section 155 having afree edge 156 may be provided in the detachable top panel portion 30 abetween adjacent end points 152 a, 152 b of the tear pattern 152. Thecut-away corner section 155 is formed by gap or opening 157 between thedetachable top panel section 30 a and the non-detachable top panelsection 30 b and enables gripping of the detachable top panel portion 30a.

Still referring to FIG. 1, a substantially transparent, flexible film158 is attached to the undersides of the top panel 30 and the first sidepanel 20 and disposed behind the detachable top panel and side panelportions 30 a, 20 a. The film 158 is visible in the area of the opening157 in the shipping carton 200 (FIG. 3) and renders at least a portionof the interior of the carton 200 visible to a user or consumer. Thefilm 158 may be adhesively or otherwise attached to the top panel 30 andthe first side panel 20 at the non-detachable top and side panelportions 30 b, 20 b, and is preferably not attached to the detachabletop and side panel portions 30 a, 20 a. In alternate embodiments inwhich the detachable panel section extends into other panels of theblank 1, the film 158 should extend behind such panels and be attachedto the blank 1 around the detachable panel section 150.

FIG. 2 shows a partially erected carton 2 formed from the blank 1. Inthis configuration, the blank 1 is folded such that the top panel 30 andbottom panel 10 extend substantially parallel to each other, the firstand second side panels 20 extend substantially parallel to each other,substantially perpendicular to the top and bottom panels 30, 10, and arear end panel 280 extends substantially perpendicular to the top andbottom panels 30, 10 and the first and second side panels 20, 40. Therear end panel 280 is formed by the second top end panel 80 and secondbottom end panel 70, which are folded such that second the top end panel80 overlaps the second top end panel 70 and is attached to the adhesiveregion 72.

In the partially erected carton 2 as configured in FIG. 2, the first andsecond side panels 20, 40 are folded with respect to the top panel 30along the fold lines 22, 34, respectively, and the bottom panel 10 isfolded with respect to the first side panel 20 along the fold line 14.The side flap 140 is folded inwardly along the fold line 12 inside ofthe side panel 40, so as to extend substantially parallel to the sidepanel 40, and is optionally adhesively attached to the underside of theside panel 40 via the adhesive region 142, for reinforcing the sidepanel 40. The first and second side end flaps 100, 110 are foldedinwardly along the fold lines 26, 46, respectively, so as to extendtransversely to the first and second side panels 20, 40. The third andfourth side end flaps 120, 130 are folded inwardly along the fold lines28, 48, respectively, so as to extend transversely to the first andsecond side panels 20, 40. The second top end flap 80 and the secondbottom end flap 70 are folded over the third and fourth side end flaps120, 130 along the fold lines 38, 18 to form the rear end panel 280,such that second the top end flap 80 overlaps the second bottom end flap70. The second top end flap 80 is attached to the adhesive region 72 onthe second bottom end flap 70, thereby forming the second end panel 280.The first top end flap 60, the first bottom end flap 50, and the firstand second side end flaps 100, 110 are not folded inward and arepositioned such that the partially erected structure 2 has an open frontend 4, thereby providing access to the interior 6 of the partiallyerected structure 2.

An item I to be stored within the fully erected carton 200 (FIGS. 3-8)may be placed in the interior 6 of the partially erected carton 2through the open front end 4 prior to storage and/or shipping. Inparticular, the item I may be an uncooked or unprepared food item, suchas a frozen or refrigerated pie, or the item may be a ready-to-eat fooditem.

FIG. 3 shows the fully erected carton 200 formed from the blank 1,wherein the carton 200 is in a configuration for shipping or storing theitem I (omitted from FIG. 3) therein. According to an embodiment of theinvention, the configuration of FIG. 3 is suitable for storing and/orshipping the item I after the item I has been placed in the partiallyerected structure 2. The carton 200 in the configuration of FIG. 3 isconfigured similarly to the partially erected carton 2, except that thecarton 200 includes a front end panel 260 formed by the first top endpanel 60 and the first bottom end panel 50, and extending substantiallyparallel to the rear end panel 280. In the configuration of FIG. 3, thefirst and second side end flaps 100, 110 are folded inwardly along thefold lines 26, 36, respectively, so as to extend transversely to thefirst and second side panels 20, 40. The first top end flap 60 and thefirst bottom end flap 50 are folded over the first and second side endflaps 100, 110 along the fold lines 36, 16, such that first the top endflap 60 overlaps the first bottom end flap 50. The first top end flap 60is attached to the adhesive regions 52 on the first bottom end flap 50,thereby forming the front end panel 260. Thus, the carton 200 fullyencloses the item I.

FIGS. 4-6 illustrate a manner in which the carton 200 can be opened fromthe configuration of FIG. 3. Referring to FIG. 4, the first top end flap60 can be detached from the first bottom end flap 50 by pulling thefastening tabs 64 outward and upward in the direction U so as to breakthe adhesive bond between the adhesive regions 52 and the first top endflap 60. Thereafter, as shown in FIGS. 5 and 6, the top and bottom endflaps 60, 50 and the first and second side end flaps 100, 110 can befolded outward to open the carton 200, and the item I can be removed.For example, when the item I (not shown in FIGS. 4-5) is a frozen,uncooked or unprepared food item, such as a pie, the item I can beremoved from the carton 200 for cooking or other preparation.

FIG. 7 shows the carton 200 in a reclosed configuration after the firsttop end flap 60 has be detached from the first bottom end flap 50 asshown in FIGS. 4, 5 and 6. In the case of an item I that has beenremoved from the carton 200 in the configuration of FIG. 6, the item Ican later be returned to the carton 200, for example after bakingcooking or other preparation, and the carton 200 can then be reclosed inthe configuration of FIG. 7. In the reclosed configuration, the firstand second side end flaps 100, 110 are folded inwardly along the foldlines 26, 36, respectively, so as to extend transversely to the firstand second side panels 20, 40. The first top end flap 60 and the firstbottom end flap 50 are folded over the first and second side end flaps100, 110 along the fold lines 36, 16, such that first the top end flap60 overlaps the first bottom end flap 50. The first top end flap 60 isfastened to the first bottom end flap 50 by the fastening tabs 64, whichare inserted in the cutouts 58 in the bottom end flap 50, therebyreforming the front end panel 260. Thus, the carton 200 fully enclosesthe item I. As illustrated in FIGS. 3-9, the cut line segments 36 a, 38a form vents in the erected carton 200 which serve to vent steam fromthe carton 200 when the item I is a warm baked item, such as a pie.

FIGS. 8 and 9 illustrate the manner in which the carton 200 can beconverted into a display configuration for displaying the item I. Asshown in FIG. 8, the detachable panel section 150 can be detached fromthe remainder of the carton 200 along the tear pattern 152 by grippingthe free edge 156 of the cut-away corner section 155, and pulling thedetachable panel section 150 up and away from the remainder of thecarton 200 in the direction Y. As shown in FIG. 9, upon completelydetaching the detachable panel section 150 from the remainder of thecarton 200, the carton 200 is converted to the display configuration. Inthe display configuration, the detachable top and side panel portions 30a, 20 a are removed and the non-detachable top and side panel portions30 b, 20 b remain with the carton, surrounding the film 158. Because thefilm 158 is substantially transparent, the film 158 forms a displaywindow in the side panel 20 and the top panel 30, through which the itemI (omitted from FIG. 9) is visible while the carton 200 is closed. Thedisplay configuration of the carton 200 is particularly useful fordisplaying the item I contained therein in a retail location. It isnoted that, alternatively, the detachable panel section 150 can first bedetached from the carton 200, and the item I can thereafter be placed inthe carton 200 for display.

The foregoing disclosure provides illustrative embodiments of theinvention and is not intended to be limiting. As understood by those ofskill in the art, the overall invention encompasses other embodimentsnot specifically enumerated herein. For example, although the carton 200is shown in the form of a parallelpipedal box, it can alternatively beshaped differently, and likewise the detachable panel section 150 andthe associated film 158 can be shaped and arranged differently (e.g., acarton may include multiple separate detachable panel sections that areinwardly covered by a film, or respectively inwardly covered by multipleseparate films). As an additional example, the fastening tabs 64 andcutouts 58 that receive the fastening tabs may be reduced or increasedin number, may be arranged differently and/or may be replaced with anyother suitable attachment mechanism(s).

1. An assembly for forming a carton, the assembly including: a cartonblank comprising a bottom panel, a first side panel foldably connectedto the bottom panel, a top panel foldably connected to the first sidepanel, a second side panel foldably connected to the top panel, aplurality of end flaps, and a detachable panel section defined by a tearpattern in the blank; and a substantially transparent film attached toan underside of the blank and disposed behind the detachable top panelsection.
 2. The assembly of claim 1, wherein the detachable panelsection comprises a detachable top panel portion disposed in the toppanel.
 3. The assembly of claim 1, wherein the detachable panel sectioncomprises a cut-away corner section configured to enable gripping of thedetachable panel section.
 4. The assembly of claim 1, wherein thedetachable panel section is disposed in at least one of the top panel,the first side panel, the second side panel, the first top end flap andan end flap of the plurality of end flaps.
 5. The assembly of claim 1,wherein: the plurality of end flaps comprises a top end flap foldablyconnected to the top panel and a bottom end flap foldably connected tothe bottom panel; and the top end flap and the bottom end flap areconfigured to be selectively attached to each other and selectivelydetached from each other for closing and opening the carton,respectively.
 6. The assembly of claim 5, comprising at least one tab inthe top end flap; and at least one cutout in the bottom end flap,wherein the top end flap and the bottom end flap are configured to befolded in overlapping relationship and releasably, adhesively securedtogether with adhesive; and the at least one tab is configured to beinserted in the at least one cutout to secure the first top end flap andthe first bottom end flap together when the top end flap and the bottomend flap are not adhesively secured together.
 7. The assembly of claim1, comprising at least one cut line segment configured to form a vent inthe carton.
 8. The assembly of claim 7, wherein the at least one cutline segment comprises a cut line segment formed in a fold line betweenone of the plurality of end flaps and the top panel.
 9. A cartoncomprising: a bottom panel; a top panel; a first side panel; a secondside panel; a first end panel; a second end panel; and a detachablepanel section in at least one of the top panel, the first side panel,the second side panel, the first end panel and the second end panel, thedetachable panel section being defined by a tear pattern; and asubstantially transparent film positioned behind the detachable panelsection.
 10. The carton of claim 9, wherein the detachable panel sectionis located in the top panel.
 11. The carton of claim 10, wherein thedetachable panel section comprises a cut-away corner section configuredto enable gripping of the detachable panel section.
 12. The carton ofclaim 9, wherein the detachable panel section is located in at least oneof the top panel, the first side panel, the second side panel, the firstend panel and the second end panel.
 13. The carton of claim 9,comprising at least one vent opening for releasing steam from thecarton.
 14. The carton of claim 13, wherein the at least one ventopening comprises a cut line segment in a fold line between the firstend panel and the top panel and/or a cut line segment formed in a foldline between the second end panel and the top panel.
 15. The carton ofclaim 9, wherein: the first end panel comprises a first top end flapfoldably connected to the top panel and a first bottom end flap foldablyconnected to the bottom panel; and the first top end flap and the firstbottom end flap are configured to be selectively attached to each otherand selectively detached from each other for closing and opening thecarton, respectively.
 16. The carton of claim 15, comprising at leastone tab in the top end flap; and at least one cutout in the bottom endflap, wherein the top end flap and the bottom end flap are configured tobe folded in overlapping relationship and releasably, adhesively securedtogether with adhesive; and the at least one tab is configured to beinserted in the at least one cutout to secure the first top end flap andthe first bottom end flap together when the top end flap and the bottomend flap are not adhesively secured together.
 17. The carton of claim 9,wherein the carton is configured to contain a pie.
 18. A method ofpreparing a food item, comprising: transporting the food item to alocation in a carton comprising a bottom panel, a top panel, a firstside panel, a second side panel, a first end panel, a second end panel,and a detachable panel section and a substantially transparent filmpositioned behind the detachable panel section, wherein the detachablepanel section is defined by a tear pattern and is located in at leastone of the top panel, the first side panel, the second side panel, thefirst end panel and the second end panel; and after transporting thefood item to the sale location, detaching the detachable panel sectionsuch that the food item can be viewed through the substantiallytransparent film.
 19. The method of claim 18, comprising: opening thecarton after transporting the food item to the sale location; removingthe food item from the carton after opening the carton; cooking the fooditem after removing the food item from the carton; placing the food iteminside the carton after cooking the food item; and reclosing the firstend panel after placing the food item inside the carton.
 20. The methodof claim 19, wherein: the first end panel comprises a top end flap and abottom end flap configured to be folded in overlapping relationship;opening the first end panel comprises breaking an adhesive bond betweenthe top end flap and the bottom end flap; and reclosing the first endpanel comprises inserting at least one tab of the top end flap in acorresponding cutout in the bottom end flap.
 21. The method of claim 18,comprising placing the carton on display after detaching the detachablepanel section.
 22. The method of claim 18, wherein the carton comprisesat least one vent opening configured to vent steam from the carton. 23.The method of claim 18, wherein detaching the detachable panel sectioncomprises gripping a cut-away corner section of the detachable panelsection and pulling the detachable panel section.
 24. The method ofclaim 18, wherein the food item is a pie.